clutch VOLKSWAGEN CORRADO 1990 Owner's Manual

A/C COMPRESSOR SERVICING
Article Text (p. 12)
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:41PMFig. 7: Hitachi 6-Cylinder Compressor (5-Cylinder Similar)
Courtesy of Nissan Motor Co., U.S.A.
HITACHI 5 & 6-CYL SHAFT SEAL R & I
NOTE: Check compressor refrigerant oil level when replacing seals.
See COMPRESSOR REFRIGERANT OIL CHECKING article in this
section.
Removal
1) Drain oil from suction port, measure oil drained and
discard oil. Remove clutch hub, pulley, bearing assembly and coil
assembly. See HITACHI 5 & 6-CYLINDER CLUTCH R & I in this article.
2) Using snap ring pliers, remove retainer ring. Remove key
and plug low and high pressure openings of compressor with Plugs
(KV994C4531, KV994C4532 and KV994C4559).
3) Insert Adapter (KV994C1552) into hole in middle of blind

A/C COMPRESSOR SERVICING
Article Text (p. 14)
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:41PM
ring and carbon seal contact surface of shaft seal seat for damage.
Make sure that "O" ring contact surface on front cover is not damaged.
Make sure refrigerant oil is applied to oil seal in shaft seal seat.
Installation
1) To install, reverse removal procedure. Ensure shaft seal
contact surface is free of dirt. Lubricate with refrigerant oil. Cap
end of compressor shaft.
2) Using Guard (KV994C1143), insert shaft seal. Be sure shaft
seal case is aligned with shaft. Apply force to turn seal to left and
right. Ensure shaft seal seats properly in shaft cut-out.
3) Fit "O" ring to outside groove of shaft seal seat. Ensure
"O" ring seats properly. Apply refrigerant oil on contact surfaces and
around shaft seal seat. Lightly coat surface of shaft with refrigerant
oil.
4) Install key on compressor shaft. Using snap ring pliers,
compress retainer ring and fit retainer ring into front cover. Seat
retainer ring firmly in groove. Thoroughly wipe grease or oil from
shaft surface.
5) Connect Installer (KV99412329) to shaft of compressor, and
turn shaft 5 or 6 times in a clockwise direction to seat seal. See
REFRIGERANT OIL & R-12 SPECIFICATIONS chart in this section for system
capacities.
MATSUSHITA ROTARY VANE CLUTCH R & I
Removal & Installation
1) Insert two 5 mm bolts into threaded holes in armature.
Using a screwdriver as lever in between bolts, remove center bolt.
remove armature and shim from shaft.
2) Remove snap ring. Using a puller, remove pulley.
Disconnect electrical leads from field coil. Remove 3 field coil
mounting bolts. Remove field coil. See Fig. 10. To install, reverse
removal procedure.Fig. 10: Exploded View of Rotary Vane Compressor (Matsushita)
Courtesy of Subaru of America. Inc.
NIPPONDENSO TV12 ROTARY VANE CLUTCH R & I

A/C COMPRESSOR SERVICING
Article Text (p. 15)
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:41PM
Removal
Remove compressor from vehicle and place on work bench.
Holding clutch with Clutch Holder (00007-10331), remove shaft nut.
Install Clutch Disc Remover (4992-02-020) and remove clutch disk and
shims. Remove pulley snap ring and tap pulley (with bearing) off of
compressor with plastic hammer. See Fig. 11.
Installation
To install, reverse removal procedure. Ensure pulley-to-
clutch disc clearance is .016-.024" (.4-.6 mm). Adjust (if necessary)
by adding or subtracting shims.Fig. 11: Exploded View of Rotary Vane Compressor (Nippondenso TV12)
Courtesy of Mazda Motors Co., U.S.A.
NIPPONDENSO 6 & 10-CYL CLUTCH R & I
Removal
1) Remove A/C compressor. Remove pressure plate shaft bolt
using socket wrench and Clutch Stopper (07112-76060). Install Clutch
Remover (07112-66040) on pressure plate. Using clutch stopper and
socket wrench, rotate clutch remover to remove pressure plate.
2) Remove shims from pressure plate. Remove snap ring from
compressor. Tap rotor off shaft with plastic hammer. Disconnect stator
wire from housing. Remove snap ring from inside stator. Remove stator.
See Fig. 12.
CAUTION: DO NOT damage pulley when tapping on rotor.
Installation

A/C COMPRESSOR SERVICING
Article Text (p. 16)
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:41PM
To install, reverse removal procedure. Ensure snap rings are
installed with beveled side up. tighten shaft bolt to 10 ft. lbs.
(14 N.m). Ensure clutch clearance is .014-.026" (.36-66 mm). adjust
clearance by adding or subtracting shims as necessary.
NIPPONDENSO 6 & 10-CYL SHAFT SEAL R & I
NOTE: Check compressor refrigerant oil level when replacing seals.
See COMPRESSOR OIL CHECKING article in the AIR CONDITIONING &
HEAT section.
Removal
1) Hold clutch hub stationary and remove center nut. Screw
remover into center of hub. Turn center bolt to remove pressure plate.
2) Remove shims from shaft. Remove snap ring from inside of
pulley. Tap pulley off of shaft with plastic mallet. Be careful not to
distort pulley while removing.
3) Disconnect clutch coil wires from compressor housing.
remove snap ring inside coil and lift coil off compressor. Pry dust
seal out from around compressor shaft (if equipped).
4) Place shaft key remover on shaft and turn to remove key.
Remove drain plug (if equipped). Remove service valves-to-compressor
body bolts. Remove valves. Discard "O" rings. Drain oil out of
compressor.
5) Remove 6 through bolts from front head of compressor and
discard washers. Tap head loose from compressor; be careful not to
scratch sealing surfaces. remove snap ring (if equipped) from front
housing. Press seal plate out. Remove seal from shaft. See Fig. 12.
Installation
1) Lubricate shaft seal with clean refrigerant oil and place
on compressor shaft. Lubricate seal plate and "O" ring (if equipped)
and install in front housing. Install snap ring (if equipped).
2) Place front housing on compressor body. Install through
bolts with new washers. Tighten bolts evenly and alternately to
18 ft. lbs. (24 N.m). Install shaft key using installer and plastic
mallet. Insert dust seal into front of compressor.
3) Install drain plug with new gasket. Add correct amount of
refrigerant oil to compressor. If service valves were removed, coat
new "O" rings with refrigerant oil and install service valves.
4) Place clutch coil on compressor and install snap ring.
Install shims on shaft to adjust pressure plate-to-rotor clearance to
.016-.028" (.41-.71 mm). Tighten shaft nut to 12 ft. lbs. (16 N.m).

A/C COMPRESSOR SERVICING
Article Text (p. 17)
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:41PMFig. 12: Nippondenso 6-Cylinder Compressor
Courtesy of Chrysler Motors.
PANASONIC ROTARY VANE CLUTCH R & I
Removal
1) Insert two 5 mm bolts into threaded holes in armature.
Using screwdriver as a lever in between bolts, remove center bolt.
Remove armature and shims from shaft.
2) remove snap ring. Using puller, remove pulley. Disconnect
electrical leads from field coil. Remove 3 field coil mounting bolts.
Remove field coil.
Inspection
Check friction surfaces for damage from excessive heat or
grooving caused by slippage. Replace parts as necessary. Check coil
winding for shorted or open winding. Clean surfaces with solvent and
dry rag.
Installation
To install, reverse removal procedure. Tighten field coil
retaining screws to 30-56 INCH lbs. (3.4-6.4 N.m). Ensure pulley-to-
armature gap is .016-.024" (.4-.6 mm). If gap is not as specified,

A/C COMPRESSOR SERVICING
Article Text (p. 18)
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:41PM
adjust by adding or removing shims. Tighten center bolt to
96-108 INCH lbs. (11-13 N.m). See Fig. 13.Fig. 13: Exploded View of Rotary Vane Compressor (Panasonic)
Courtesy of Chrysler Motors.
PANASONIC ROTARY VANE SHAFT SEAL R & I
Removal & Installation
Remove clutch and coil. Remove seal plate snap ring. Using
seal plate remover, engage seal and remove seal plate. Using seal
remover, engage seal ears and remove seal. See Fig. 14. To install,
reverse removal procedure. Coat new seal plate and seal with clean
refrigerant oil before installing. DO NOT touch seal surfaces with
fingers.

A/C COMPRESSOR SERVICING
Article Text (p. 19)
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:41PMFig. 14: Removing Rotary Vane Compressor Shaft Seal (Panasonic)
Courtesy of Chrysler Motors.
SANDEN SCROLL CLUTCH & SHAFT SEAL R & I
NOTE: Check compressor refrigerant oil level when replacing seals.
Removal
1) Secure 2 box-end wrenches, to hold armature plate, using
two 6 mm bolts 1 in. (25 mm) or longer. Holding box-end wrenches, use
a socket and ratchet to remove clutch hub nut.
2) Remove armature plate. See Fig. 15. Remove snap ring with
internal snap ring pliers. Remove clutch hub. Remove snap ring and
clutch coil.
3) Remove bolts retaining front housing. Remove front housing
and "O" ring from compressor. Remove shaft seal from shaft. Remove
snap ring from back side of front housing. Remove seal plate.
4) Use brass drift and hammer to lightly tap shaft bearing
from front housing. Remove felt seal.
NOTE: Do not touch the sealing surfaces of the shaft seal carbon
ring and shaft seal plate.
Installation
1) Lubricate shaft seal with compressor oil. Align notches on
shaft seal with notches on crank shaft. Install shaft seal plate on
the front housing. Install front seal housing to compressor.
2) Use Press Tool (MB991301) to install felt into front
housing. Make sure felt metal section faces up. Use Press Tool

A/C COMPRESSOR SERVICING
Article Text (p. 20)
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:41PM
(MB991301) to press bearing into front housing.
3) Align and install clutch coil. Install snap ring so that
the tapered surface is facing outward. Install clutch hub. Install
snap ring. Install armature plate, aligning raised area to notch.
4) Secure 2 box-end wrenches, to hold armature plate, using
two 6 mm bolts 1 in. (25 mm) or longer. Holding box-end wrenches, use
a socket and ratchet to tighten clutch hub nut to 12 ft. lbs. (16 N.
m).
5) Use feeler gauge to measure distance between armature and
clutch hub. If gap is not .01-.02" (.25-.51 mm), remove clutch
assembly and add or remove shims accordingly. See Fig. 13.Fig. 15: Sanden Scroll Compressor
Courtesy of Chrysler Motors.
SANDEN 5-CYL CLUTCH R & I
Removal
1) Hold clutch hub stationary and remove shaft nut. Remove
clutch plate using puller. Remove external front housing snap ring and
internal bearing snap ring. See Fig. 16.
2) Install puller and pull rotor assembly off. remove 3
screws and clutch coil. Use driver and hammer to drive bearing out
from hub.
Installation
1) Install new bearing; ensure installer contacts outer race
of bearing. Install snap ring and ensure bearing turns freely. Install

A/C COMPRESSOR SERVICING
Article Text (p. 21)
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:41PM
clutch coil on compressor.
2) Support compressor on rear mounting ears. Align rotor on
front housing hub. Use adapter and press to install rotor (or drive
into place with soft mallet). After rotor is seated, install front
snap ring.
SANDEN 5-CYL SHAFT SEAL R & I
NOTE: Check compressor refrigerant oil level when replacing seals.
Removal
1) Hold clutch hub stationary and remove shaft nut with thin
wall socket. Use clutch plate puller to remove clutch plate. Tap key
out of slot in crankshaft.
2) Remove seal retainer with seal remover and 3/4" socket
wrench. Use seal seat remover tongs to pull seal seat off compressor
shaft. Insert seal remover into front housing and turn to engage tangs
on seal. Lift seal out. Remove seal "O" ring from front housing, being
careful not to scratch shaft.
Installation
1) Coat "O" ring with refrigerant oil and install into
groove. Load a new seal onto installer, being careful not to touch
carbon sealing surface with fingers. Install shaft protector. Dip seal
in refrigerant oil and install on shaft. Rotate seal clockwise until
seal fits into flats on shaft. Remove seal installer by turning
counterclockwise.
2) Coat seal seat with refrigerant oil and install with
tongs. Reinstall seal seat retainer (with flat side down). Install
shims and shaft key. Rotate shaft several times to help break in seal.
3) Use a press to install clutch plate. Make sure that air
gap is .016-.031" (.41-.79 mm). Hold plate stationary and install
shaft nut.

A/C SYSTEM GENERAL DIAGNOSTIC PROCEDURES
Article Text (p. 5)
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:41PM
and on too rapidly. Switch
NORMAL NORMAL Cycling clutch systems only - Misadjusted
to compressor doesn't turn on Thermostatic
HIGH soon enough. Discharge air Switch or
becomes warm as low side Defective
pressure rises. Pressure
Sensing Switch
LOW LOW Bubbles in sight glass. Low R-12
Outlet air slightly cool. Charge
LOW LOW Sight glass clear. Outlet Excessively
air very warm. Low R-12
Charge
LOW LOW Outlet air slightly cool. Expansion
Sweating or frost at Valve Stuck
expansion valve. Closed Screen
Plugged or
Sensing Bulb
Malfunction
LOW LOW Outlet air slightly cool. Restriction
High side line cool to touch. on High Side
Sweating or frost on high
side.
LOW HIGH Evaporator outlet pipe cold. STV Stuck
Low side goes into vacuum Open
when blower is disconnected.
HIGH LOW Evaporator outlet pipe warm. STV Stuck
Outlet air warm. Closed
HIGH LOW Noise from compressor. Compressor
Malfunction
HIGH HIGH Outlet air warm. Liquid Compressor
line very hot. Bubbles in Malfunction
sight glass. or R-12
Overcharge
HIGH HIGH Outlet air slightly cool. Large Amount
Bubbles in sight glass. of Air and
Moisture in
System
HIGH HIGH Outlet air warm. Evaporator Expansion
outlet sweating and frost. Valve
Stuck Open
(1) - If equipped with a low refrigerant charge protection system,
compressor operation may have stopped.ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄEND OF ARTICLE